Arc welding apparatus



April 21-,-F-;1 942. v. J. CHAPMAN ARC WELDING APPARATUS Original Filed Aug. 9. 1940 3 Sheets-Sheet l Inventor: Verm J. Chap an Hls Attovney April 1942. v. J. CHAPMAN 2,280,628

ARC WELDING APPARATUS Original Filed Aug. 9, 1940 3 Sheets-Sheet 2 Inventor: Verni J. Chapman, WW6

His Attorney p i 94 v. J. CHAPMAN 2,280,628

ARC WELDING APPARATUS Original Filed Aug. 9, 1940 s Sheets-Sheet :5

Ihventor: Verni J. Chapman,

629 by His Attorney Patented Apr. 21, 1942 ARC WELDING APPARATUS Verni J. Chapman, Schenectady, N. Y., assignor to General Electric Company, a corporation of New York Original application August 9, 1940, Serial No. 351,995. Divided and this application August 11, 1941, Serial No. 406,387

Claims.

however, be performed by using flux coated stick electrodes such as are used for hand welding.

It is an object of my invention to provide for automatic arc welding machines, a new and improved holder for flux coated or bare stick electrodes. Flux coated stick electrodes have one end bared of flux for clamping and supplying welding current thereto.

It is a further object of my invention to provide for automatic arc welding machines a stick electrode feeding attachment which is easy to load, holds the arcing terminal of an electrode at a desired point of welding and automatically ejects the stub end of a used electrode when returned to its loading position for a new electrode.

Other objects of my invention will become apparentfrom the following description of the arc welding apparatus illustrated in the accompanying drawings.

In the accompanying drawings Fig. -1 shows an automatic arc welding machine having a stick electrode feeding attachment which embodies my invention; Figs. 2, 3, and 4 are views of the work holding and traversing means of this machine; Fig. 5 is a side view with parts broken away showing the stick electrode feeding attachment of this machine; Fig. 6 is a section along lines 86 of Fig. 5; Fig. 7 is a section along lines 1-! of Fig. 5; Fig. 8 is a view showing the selfeiecting characteristics of the electrode feeding attachment; and Fig. 9 is a wiring diagram showing the circuits including and controlled by the limit switches associated with the electrode feeding attachment.

According to my invention, the electrode feeding attachment is provided with an electrode holder having jaws against which opposite sides of one portion of a stick electrode is held when the electrode is bent to latch another portio v thereof against a gmde forming part of the electrode feeding attachment. As a result of this arrangementthe electrode is securely held during its feeding toward and away from the work,

but when the electrode is moved away from the work until it passes beyond its guide, the bending stresses which hold the electrode in the jaws of the holder are released so that the electrode either falls or may be easily removed therefrom for the insertion of a new electrode.

The apparatus shown in the drawings also embodies means for traversing a line of welding on work of irregular contour past the arcing terminal of the electrode which rests against the guide forming part of my feeding attachment. This traversing means forms the subject matter of my application Serial No. 351,995, filed August 9, 1940 for Automatic arc welding apparatus.

The apparatus shown in the drawings also embodies means which not only terminates each of a series of welding operations capable of being performed with the same stick electrode after predetermined lengths of the electrode have been consumed in these welding operations, but which also automatically returns the electrode holder to its loading position by suitably controlling its feeding means after the last welding operation has been terminated. This control apparatus forms the subject matter of my application Serial No. 406,388 filed Aug. 11, 1941, for Arc welding apparatus, which application, like the present application, is a division of my above referred to application Serial No. 351,995.

Referring to Figs. 1 and 2 of the drawings, an electrode feeding attachment i0 embodying my invention is mounted on a welding head II and propelled by the feed rolls I! of this welding head. The welding head is illustrated as having the construction disclosed and claimed in United States Letters Patent 2,170,673, Jasper E. Anderson, granted August 22, 1939 and assigned to the assignee of this invention. It is supported on a crank shaped arm i3 which is mounted on a pillar I4 forming part of the welding machine frame. As illustrated in the drawings, this welding head is adjustable on arm l3 and this arm is adjustable on pillar I4 so that the arcing terminal of the electrode l5 held and guided by the electrode feeding attachment in may be positioned at a desired point of welding over the work.

The work i6 is supported on a turntable i1 so that the line of welding i8 thereon is parallel to and in register with a flanged cam I9 having a. configuration corresponding to the line of welding. This cam is mounted on the side of the turntable opposite its work supporting sur face. This work surface or a member 20 mounted on the turntable and forming a part thereof is so shaped as to position the work with its line of welding parallel to and in register with cam l9. The work illustrated in the drawings is a float valve chamber formed of two sheilshaped halves which are initially assembled by spot welds between their flanged edged portions which are to be arc welded in order to complete the assembly.

'Turntable i1 is mounted for rotation and translation relative to the head stock 2| of the welding machine. It is guided in its movement by a plurality of balls 22 held in ball races 23 which are supported on the end 24 of the head stock opposite thereto. It is supported through the agency of cam IS on a feed roll 25 which is mounted on one end of a shaft 26 journaled in bearings located in the two ends 24 and 21 of the head stock of the machine. Shaft 26 and feed roll 25 are turned about their longitudinal axes by travel motor 28 which is con- 'nected through gears 29 to impart rotation thereto.

As shown'in Figs. 2 and 3, cam I9 is held on feed roll 25 by a pressure roll 30 having a flanged edged portion 3| which enters a groove 32 in v the outside surface portion of cam l9. Pressure roll 30 is mounted for rotation about one end of a lever 33 whose other end is pivoted at 34 to a frame 35. This frame is mounted for rotation about shaft 28 and its adjustment about this shaft causes roll 3! to swing in an are about the axis of rotation of feed roll 25 as shown by the dotted lines in Fig. 3. Lever 33 is biased toward frame 35 by a spring clamp 38 mounted on the frame. justing rod 31 which extends through a slot in the head stock of the machine and through a cover plate 38 for this slot. Its projecting end portion is provided with hand wheels 40 for adjusting the pressure which the spring clamp exerts on lever 33 as well as for rotating and positioning frame 35 relatively to the head stock of the machine. A slot 33 in end plate 24 of the head stock permits the movement of lever 33 resulting from this adjustment.

The rotational adjustment of pressure roll 30 about feed roll 25 shifts the point of tangential engagement of these rolls with cam it relatively to the head stock 2i of the welding machine.

Since the point of welding is determined by and is opposite the point of engagement of rolls 25 and 33 with cam is, the adjustment thus provided makes it possible to shift the point of welding relative to the frame of the machine on which the welding head is mounted. For example, in welding the float valve chamber illustrated, it was found desirable to weld in a down-sloping position and the rolls 23 and 30 were so adjusted as to position the work relatively to the head stock of the machine to accomplish this.

Welding current is supplied to the work through turntable l'l, cam I 3, feed roll 25, shaft 23 and brushes 4! from one terminal of a source of supply through conductor 42. The other terminal 43 of this source of supply is connected to the. electrode holding portion of feeding attachment Hi.

The work holding surface of the turntable may be proportioned and arranged to provide a substantially airtight engagement with the surface of'the work part It resting thereagainst. If the chamber thus formed between the tumtable and the work is connected with a vacuum line, atmospheric pressure may be employed for initially holding the work on the turntable.

This clamp is provided with an ad- Such an arrangement has been illustrated in Fig. 2 where the vacuum line H is connected through a valve 45 and a conduit 46 to the chamber formed between the turntable and the work. The end of conduit 46 may be provided with a ball and socket joint and the conduit itself may be in part flexible as illustrated in order to accommodate the rotation and translation of turntable ll relative to the frame of the machine on which valve 43 is supported.

A clamping pressure is applied to the work l6 through a tail stock mechanism diagrammatically illustrated at 41 in Fig. 2. This tail stock mechanism forms a part of the welding machine and is mounted on its frame. A work engaging member 48 is moved to and from the work by the movement of a lever 43 pivoted at one end in a support Ill attached to the frame of the machine. A piston rod 5| pivotally attached to a mid portion of lever 49 constitutes in combination with the fluid operated double acting piston and cylinder 52 means for moving lever 43 toward and away from the work about its pivotal support in member 50. Fluid under pressure is supplied to and exhausted from opposite ends of cylinder 52 through a valve 52. which is properly positioned to obtain the desired movement.

As shown in Fig. 4, the upper end of lever 43 is connected through a link 54 to a supporting member 55 for the work engaging member 43. Member 55 is tubular and mounted for sliding movement toward and away from the work in tubular guide 58 which is attached to the frame of the welding machine. Work engaging member 48 is also tubular in shape and has a work engaging cup 51 at one end thereof. Its other end is provided with a stud 58 threaded into the end thereof. This stud forms a support for a round spring rod 53 whose outer end extends through a round opening in a block ill mounted within support member 55. A ball bearing BI is located on stud 53 and held in place thereon by a nut 82 threaded onto the outer end portion of stud 53. The outer race of this ball bearing is held against an internal shoulder in the end of support member 58 by a collar 33 which is attached to the inside surface of the end of member Bl by screws 34. This race has a spherical ball engaging surface so that the connection between the work enga ing member 43 and its support member 55 forms a ball and socket joint of rotation which permits the work engaging member 43 to accommodate itself to the rotational and translational movement imparted to the work it by the turntable I! on which it is supported. The opening between the work engag-' ing member 43 and its support member 55 is closed by a felt washer I held in place by a :gllar 63 mounted on and attached to member The tail stock mechanism is insulated from the frame of the machine so that welding current must be supplied to the work It by way of turntable II on which it is supported. By thus confining the direction in which welding current is supplied to the work, better welding conditions are established.

The stick electrode feeding attachment, which positions the arcing terminal of electrode I! over the desired line of welding, is best illustrated in Figs. 5, 6, 7, and 8. It comprises an electrode guide 61 mounted on the lower end of a member 68 whose upper end is attached to and electrically insulated from one end of an angular frame 39 whose other end is attached to the welding head some II. It also comprises a holder 18 which is slidably mounted on member 88. This holder is provided with jaws II whose electrode -engaging surfaces are out of line with the electrode-engaging surface of guide El and which cramp and hold the end of an electrode which has been stressed by bending to bias its other end against said guide. Welding current is supplied through conductor 48, above referred to, to holder 18 and thence to electrode I5.

Electrode holder 18 is fed toward and away from electrode guide by a feed rod I2 mechanically attached thereto but electrically insulated therefrom. This feed rod is engaged by feed rolls I2 of welding head II, and the motion thus applied to feed rod 12 is transferred to the electrode I5 through holder 18. This holder is guided along member 88 and is free to move relative thereto in the plane of the bent electrode in order to accommodate itself to the action of the bent electrode and the resistance imposed thereto by feed rod 12. The feeding attachment is positioned relative to the line of welding so that the plane of the bent electrode is directed along the line of welding. Lateral movement ofthe electrode relative to the line of welding is thus prevented.

By reason of the construction of the electrodeholding and guiding means, as shown in Fig. 8, movement of holder 18 away from guide 61 withdraws the stub end of a used electrode I5 from guide 81, thus releasing the cramping force which held it in holder 18. The stub end 'is thus free to drop from the holder during its return movement to a loading position such as illustrated in Fig. 5. The ease with which a new electrode may be inserted in the feeding attachment and its selfejecting nature are very val-. uable characteristicsto an operator who is thus enabled to perform more welding within a given period of time. The electrode guiding feature of this attachment also makes it possible to locate the arcing terminal of a stick electrode at a desired point of welding, which is of considerable importance when welding along an irregular seam. such as at" of work I6.

As shown in Figs. 1, 5, and 6, limit switches I8, 14, 15, I8, and I1 are mounted through the agency of a tube I8 on welding head II. This tube encloses feed rod I2 of the feeding attachment and a pin 18 on this rod extends through a slot in the tube to engage and operate the limit switches. These limit switches form part of a control circuit diagrammatically illustrated in Fig. 9 for controlling the feed motor ofthe welding head in response to the travel of the electrode feeding attachment to supply measured lengths of electrode during each of a series of welding operations after which the feeding attachment is returned to its loading position for a new electrode. These switches may be of any suitable type but are preferably snap actuated switches. They are operated by resilient arms 88 which are in the path of movement of pin 18.

This pin in its travel snaps by the ends of arms 88 of switches 14 and 15 located intermediate the remaining switches. The relative spacing of the limit switches determines the -measured lengths of electrode fed during each welding operation. This length of electrode corresponds in the particular arrangement illustrated to that required for welding seam I8 of float valve I8.

In the control diagram of Fig. 9, the contacts of the various limit switches have been identified by the same reference numerals applied to the switch asa whole in Figs. 1, 5 and 6. These switches have been illustrated in the positions they assume before being operated by pin I8 attached to feed rod I2 of the stick electrodefeeding attachment. The electromagnetic relays and switches have been illustrated in their deenergized positions.

In Fig. 9 turntable I'l upon which the work is supported and electrode feeding attachment I8 have been partially represented. The arc welding electrode held and guided by the feeding attachment is moved toward and away from the work to strike and maintain a welding are by the action of the welding head feed rolls l2 on feed rod 12 of the feeding attachment I8. These rolls are connected to and propelled by a feed motor 8|. The speed and direction of rotation ,of this feed motor is controlled in response to the voltage between the electrode and the work so that feeding attachment I8 driven thereby advances the electrode to and from the work to strike and maintain an arc of predetermined voltage. The control illustrated in Fig. 9 'is of the valve circuit type embodying electric valves 82 and 83 and their control 84 which is connected through conductors 85 to the arc welding electrode supported in feeding attachment I8 and to the turntable I'I upon which the work is supported; This control may be that illustrated in United States Letters Patent 2,175,017, William D. Cockrell granted October 3, 1939 and assigned to the assignee of the present invention, in which case the electric valves 82 and 83 shown in Fig. 9 correspond to electric valves 8 and I of the circuit disclosed in said Letters Patent.

In Fig. 9 feed motor 8I may be started and stopped by the operator through the agency of a start switch 86 and a stop switch 81. The closure of switch 86 connects the operating winding 88 of relay 88 across a source of alternating current supply 88. Relay 88 controls through its contacts 8I the energization of the operating winding 82 of relay 83 and through its'contacts 84 the energization of the operating winding 85 of the electromagnetic switch 88.

The operation of either relay 88 or relay 83 completes through their contacts 81 and 88 the connection of feed motor 8| through electric valves 82 and 83 to the source of supply 88. When both of these relays are deenergized, their contacts 81 and 88 complete a dynamic braking circuit for feed motor 8|. Relay 83 is also provided with contacts 88 which are connected in shunt to the contacts of limit switches 86.

Electromagnetic switch controls the connection of terminals 42 and 43 of the source of welding current and voltage to the welding electrode and the work through circuits previously traced in describing the physical structure of my machine. It is also provided with contacts I8I which control the energization of travel motor I 28 by connecting it to a source of supply I82.

Contacts I88 of this electromagnetic switch are in shunt to resistor I84 which is connected in circuit with its operating winding 85.

The nature of the control circuit shown in Fig. 9 will be better understood from a consideration of its operation. When the stick electrode feeding attachment I8 is in the position shown in Fig. 5, limit switch 13 will be open. Otherwise the various parts of the system will assume the positions illustrated.

When the operator closes start switch 88, winding 88 of relay 88 is connected across the source of supply 88 through the contacts of this start switch and the contacts of stotggowictfh This r will ently opera we con,- t c t: N, om contacts II and transfer the connection through its lower set of contacts II to its upper set of contacts 91. The closure of contacts 94 of relay 8! completes an energizing circuit for the operating winding SI of electromagneticswitchlacroasthesourceofsupplyil through resistance ill, limit switches 14, II and TI, and stop switch 81. The closure of these contacts also completes a holding circuit for the The closure of contacts 9! of relay it completes a holding circuit for its operating winding around the contacts of limit switch I. and the transfer of connections from its lower contacts II to its upper contacts 98 completes the feed motor circuit through electric valves 82 and 83 across the source of supply ll. Since the welding circuit has been opened at contacts Ill of electromagnetic switch it, there will be no voltage between operating windings II and ll of relay .9 and electromagnetic switch it from the right-hand terminal of the source of supply ll through conductor Ill, limit switches ll, Ii and I1 and stop switch '1 to the left-hand terminal of the source of supply 90. The closure of the upper set of contacts 91 of relay ll connects feed motor ll acros the source of supply 9| through electric valves 82 and 83.

The energization of winding of electromagnetic switch 96 connects through its contacts I" the terminals 42 and 43 of the source of welding current and voltage to the electrode and work, and the closure of its contacts Ill connects travel motor 28 across its source of supply I 02. The opening of its contacts I03 inserts resistance I04 in circuit with its operating winding 85 to reduce the holding current below that required for pick-up.

It will thus be seen that by closing start switch 86, the source of welding current and voltage is applied to the electrode and the work, travel between the electrode and the work is instituted by energizing motor 28 and feed motor 8| is subject to the control of N in response to the voltage across the electrode and the work to feed the electrode toward and from the work to strike and maintain a welding arc of predetermined voltage.

As the welding electrode is consumed during a welding operation thus initiated, the feeding at tachment It is fed towardthe work and eventually limit switch 14 is opened by the engagement of pin 19 of feed rod 12 with the operating arm II ofthis limit switch. The opening of limit switch H deenergizes the operating winding 88 of relay 89 and the operating winding 95 of electromagnetic switch 96. They consequently return to the positions illustrated in Fig. 9 and thereby interrupt the supply of welding current and voltage to the electrode and work and deenergize travel motor 2| and electrode feed motor ll.

When the operator again closes start switch 8, another welding operation is initiated. This operation continues until limit switch 15 is opened by the travel of feed rod 12 attached to the electrode feeding attachment ll. Thereafter, the

operator by closing the start switch I6 may institute a third welding operation which will continue until limit switches 16 and II are operated by pin Non feed rod 12 of feeding attachment II. The operator must hold the start switch closed for the secondand third welding operations until the holding circuit is completed ty the respective closing of limit switches 14 and 15.

The opening of limit switch Tl interrupts the welding operation in the manners previously described. The operation of limit switch 76, however, completes an energizing circuit for operating winding 92 ofthe relay from the righthand terminal of the source of supply Bl through contacts ill of relay 8! and limit switch 13 to the other terminal of the source of supply it.

the electrode and the work and control It for feed motor II will operate to propel the feeding attachment ll away from the work until pin II on feed rod I2 eventually opens limit switch 'l3 whereupon-the various parts of the control circuit of Fig. 9 return to the positions illustrated with the exception, of course, of limit switch 13 which will be open.

It will thus be seen that the control illustrated functions to feed measured lengths of stick electrode during each of a series of welding operations and then returns the feeding attachment to its loading position for the insertion of a new electrode. It is to be noted that all this is accomplished through the agency of the control provided for the electrode feed motor which consequently not only feeds attachment It to strike and maintain a welding arc and to compensate for the consumption of measured lengths of electrode but also after the total consumption of the electrode reaches a predetermined maximum returns the feeding attachment to a loading position for the insertion of a new electrode.-

The control of Fig. 9 is enclosed within the cabinet I06 of the machine of which it forms a part as illustrated in Fig. 1 of the drawings. A control board I 01 is also provided for adjusting the voltage of the welding are, indicating the arc welding current and voltage, adjusting the speed of the travel motor and the like.

During welding, the operator is protected from the welding are by a cylindrical enclosure I which is provided with a cover I08 rotatably supported on rollers l I 0. This cover is provided with a light controlling window Ill through which the welding operator may view the welding operation when cover I09 completes enclosure Ill. The electrode feeding attachment It extends through a slot at the left-hand end of closure I 08.

In view of the description of the operations above given of the several parts of my machine, the operation of the machine as a whole will not be restated here since 'it is obvious.

It is apparent that the many features of my invention above described may be variously .nodifled without departing therefrom, and I aim consequently in the appended claims to cover all to cramp and hold opposite sides of one portion of an electrode which has been stressed by bending to latch another portion thereof against said guide surface, and means for moving said members relatively to one another.

2. An electrode holding and feeding means comprising an electrode guide, an electrode holder having electrode engaging surfaces which are out of line with the electrode engaging surface of said guide and which cramp and hold one end of an electrode which has been stressed by bending to bias its other end against said guide, and

,means for moving said guide and said holder relatively to one another.

3. Are welding apparatus comprising a feed rod, a support therefor, a guide attached to said support, an electrode holder attached to said feed rod and slidably mounted on said support, and means for moving said rod and said holder relatively to said 'guide, said guide having a surface which is adapted to makea sliding engagement with a side surface of an electrode one end of which is inserted in said holder between opposite surfaces thereof which are positioned relative to one another and said guide surface so that an electrode engaged by all of said surfaces is bent and held in position against themby its own resiliency.

4. Apparatus for feeding arc welding electrodes comprising a guide having a surface adapted to making a sliding engagement with a side surface of an electrode, a holder having surfaces which are out of line with said guide surface and which cramp and hold the end portion of said electrode when it has been stressed by bending to bias its other end against said guide surface, means for supplying arc welding current to an electrode engaging surface of said holder, a feed rod attached to said holder, a support for said guide and said rod, means for feeding said rod and said holder relatively to said support toward and away from said guide, and a sliding connection between said holder and said support for guiding them relatively to one another.

5. Are welding apparatus comprising an electrode guide, an electrode holder having electrode engaging surfaces which are out of line with the electrode engaging surface of said guide and which cramp and hold one end of an electrode which has been stressed by bending to locate its other end in said guide, a support, means for feeding said holder relatively to said support toward and away from said guide, a sliding connection between said holder and said support limiting movement therebetween to the plane of said bent electrode, and means for positioning said support to direct said plane of limited movement of said sliding connection along the line of welding.

VERNI J. CHAPMAN. 

